Integrated transformer

ABSTRACT

A transformer comprises a first magnetic core that defines a first channel and a second magnetic core that defines a second channel, wherein the first magnetic core is coupled to the second magnetic core. First and second posts are positioned within the first channel and within the second channel, wherein each of the first and second posts extend from the first magnetic core to the second magnetic core. A primary winding and a secondary winding of a transformer are formed around the first post. An inductor winding is formed around the second post. The inductor winding is electrically coupled to the primary winding providing the transformer with increased inductance. A thermal potting compound is disposed between the first and the second cores and used to conduct heat to a heatsink.

CROSS-REFERENCES TO OTHER APPLICATIONS

This application claims priority to the following commonly-assigned Chinese provisional patent applications: Serial No. 202210993190.6, filed on Aug. 18, 2022, Serial No. 202210777120.7, filed on Jul. 1, 2022, and Serial No. 202210995777.0, filed on Aug. 18, 2022, which are each hereby incorporated by reference in their entirety for all purposes. This application is also related to the following concurrently-filed and commonly-assigned U.S. patent applications: Ser. No. ______, entitled “BI-DIRECTIONAL POWER CONVERTER MODULE,” filed ______ (Atty. Docket No. 096868-1346409-007200US), and Ser. No. ______, entitled “INTEGRATED VOLTAGE REGULATOR,” filed ______ (Atty. Docket No. 096868-1346146-007100US), which are also hereby incorporated by reference in their entirety for all purposes.

FIELD

The described embodiments relate generally to transformer and magnetics. More particularly, the described embodiments relate to an integrated transformer and inductor.

BACKGROUND

Magnetic transformers are crucial in the application of power processing systems. The development of high-speed power electronic switches requires advanced integrated magnetics with low parasitic leakage inductance. Current technologies cannot meet the need for significantly reduced leakage inductance.

SUMMARY

In some embodiments a transformer comprises a first magnetic core defining a first channel and further includes first and second posts disposed within the first channel. A second magnetic core defines a second channel and further includes third and fourth posts disposed within the second channel, wherein the first magnetic core is coupled to the second magnetic core such that the first post is aligned with the third post and the second post is aligned with the fourth post. A primary winding of wire is formed around the first and third posts and a secondary winding of wire is formed around the first and third posts. An inductor winding of wire is formed around the second and fourth posts, wherein the inductor winding is connected in series with the primary winding.

In some embodiments a void is defined between the first and the second magnetic cores and a thermally conductive potting compound is disposed within the void. In various embodiments the first post is separated from the third post by a gap. In some embodiments the first and the second magnetic cores each have U-shaped bodies. In various embodiments the first and the second magnetic cores each have L-shaped bodies. In some embodiments the L-shaped bodies define an open side of the transformer that exposes a portion of the primary winding, a portion of the secondary winding and a portion of the inductor winding. In various embodiments the first magnetic core and the second magnetic core define a notch that extends to the first and the second channels.

A In some embodiments a transformer comprises a first magnetic core defining a first channel and a second magnetic core defining a second channel, wherein the first magnetic core is coupled to the second magnetic core. A first post is positioned within the first channel and within the second channel, the first post extending from the first magnetic core to the second magnetic core. A second post is positioned within the first channel and within the second channel, the second post extending from the first magnetic core to the second magnetic core. A primary winding of wire is formed around the first post, a secondary winding of wire is formed around the first post and an inductor winding of wire formed around the second post.

In some embodiments the inductor winding is connected in series to the primary winding. In various embodiments the first post is formed from a portion of the first magnetic core and from a portion of the second magnetic core. In some embodiments the second post is formed from a portion of the first magnetic core and from a portion of the second magnetic core. In various embodiments the second post is separate from the first magnetic core and the second magnetic core. In some embodiments the first magnetic core defines a first protrusion formed in the first channel and the second magnetic core defines a second protrusion within the second channel, wherein the second post includes a first end that is in contact with the first protrusion and includes a second end that is in contact with the second protrusion. In various embodiments the first and second magnetic cores are made from a first magnetic material and the second post is made from a second magnetic material, wherein the first magnetic material is different than the second magnetic material. In some embodiments a void is defined between the first and the second magnetic cores and a thermally conductive potting compound is disposed within the void. In various embodiments the first and the second magnetic cores each have U-shaped bodies.

In some embodiments a method of forming a transformer comprises forming a first magnetic body defining a first channel and further including first and second posts disposed within the first channel. A second magnetic body is formed defining a second channel and further including third and fourth posts disposed within the second channel. The first magnetic body is coupled to the second magnetic body such that the first post is aligned with the third post and the second post is aligned with the fourth post. A primary winding of wire is formed around the first and third posts. A secondary winding of wire is formed around the first and third posts. An inductor winding of wire is formed around the second and fourth posts and the inductor winding is connected in series with the primary winding.

In some embodiments the method further comprises forming a notch or cutout in a portion of the first and the second magnetic bodies and depositing a thermally conductive potting compound between the first magnetic body and the second magnetic body. In various embodiments the first and the second magnetic bodies are each U-shaped. In some embodiments the first and the second magnetic bodies are each L-shaped.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a simplified exploded view of an integrated transformer and inductor, according to embodiments of the disclosure;

FIG. 2 illustrates a simplified isometric assembled view of the integrated transformer and inductor shown in FIG. 1 ;

FIG. 3 illustrates a simplified electrical schematic of the integrated transformer and inductor shown in FIGS. 1 and 2 ;

FIG. 4 illustrates a simplified exploded view of another embodiment of an integrated transformer and inductor, according to embodiments of the disclosure;

FIGS. 5A and 5B illustrate simplified isometric views of another embodiment of an integrated transformer and inductor, according to embodiments of the disclosure;

FIGS. 6A and 6B illustrate simplified isometric views of another embodiment of an integrated transformer and inductor, according to embodiments of the disclosure;

FIGS. 7A and 7B illustrate simplified isometric views of another embodiment of an integrated transformer and inductor, according to embodiments of the disclosure;

FIGS. 8A and 8B illustrate simplified isometric views of an integrated transformer, according to embodiments of the disclosure; and

FIGS. 9A and 9B illustrate simplified isometric views of another embodiment of an integrated transformer, according to embodiments of the disclosure.

DETAILED DESCRIPTION

Several illustrative embodiments will now be described with respect to the accompanying drawings, which form a part hereof. The ensuing description provides embodiment(s) only and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the ensuing description of the embodiment(s) will provide those skilled in the art with an enabling description for implementing one or more embodiments. It is understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of this disclosure. In the following description, for the purposes of explanation, specific details are set forth in order to provide a thorough understanding of certain inventive embodiments. However, it will be apparent that various embodiments may be practiced without these specific details. The figures and description are not intended to be restrictive. The word “example” or “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment or design described herein as “exemplary” or “example” is not necessarily to be construed as preferred or advantageous over other embodiments or designs.

Some embodiments of the disclosure relate to a transformer that is integrally formed with an inductor which may be particularly useful for electric vehicles. More specifically, techniques disclosed herein relate to transformers that are integrally formed with an inductor that is coupled in series with the primary winding of the transformer to provide the transformer with an increased series inductance.

For example, in some embodiments a first core is made from a first magnetic material and includes a first generally U-shaped body defining a first channel. Within the first channel is a first post and a second post. A second core is made from a second magnetic material and includes a second generally U-shaped body defining a second channel. Within the second channel is a third post and a fourth post. The first core is configured to be mated to the second core such that physical contact occurs between first and second generally U-shaped bodies, between first and third posts and between second and fourth posts.

A primary winding and a secondary winding are formed around first post/third post to form a transformer circuit. In some embodiments the primary winding may be interleaved with the secondary winding (e.g., the primary winding and the secondary winding arranged in alternating layers). An inductor winding can be formed around the first post/third post to form an inductor. The inductor winding may be electrically coupled to the primary winding.

A void may be defined between the first core and the second core and can be filled with a material such as, for example a thermally conductive potting compound which can be used to thermally coupled one or more surfaces of the integrated transformer to a heatsink to remove thermal energy from the assembly.

In another example the two magnetic bodies may be used to form a transformer where the primary and secondary windings are distributed across the two posts. In further embodiments, one or more of the posts may be made from a separate magnetic material and may be sized and configured to fit within pockets formed in the magnetic bodies.

In order to better appreciate the features and aspects of integrated transformer assemblies according to the present disclosure, further context for the disclosure is provided in the following section by discussing one particular implementation of a two-post configuration. These embodiments are for example only and other embodiments can have any suitable number of posts including three or more, four or more, five or more, etc.

FIG. 1 illustrates a simplified isometric exploded view of an integrated transformer and inductor 100, according to embodiments of the disclosure. This particular embodiment of integrated transformer 100 includes two separate magnetic cores. First core 105 is made from a first magnetic material and includes a first generally U-shaped body 110 defining a first channel 115. Within first channel 115 is a first post 120 a and a second post 120 b. First channel 115 may have one or more first relief regions 125 that provide room for windings, as described in more detail below.

Second core 130 is made from a second magnetic material and includes a second generally U-shaped body 135 defining a second channel 140. Within second channel 140 is a third post 120 c and a fourth post 120 d. Second channel 140 may have one or more second relief regions 145 that provide room for windings, as described in more detail below.

First core 105 is configured to be mated to second core 130 such that physical contact occurs between first and second generally U-shaped bodies 110, 135, respectively, between first and third post 120 a, 120 c, respectively and between second and fourth post 120 b, 120 d, respectively. In some embodiments second post 120 b may be separated from fourth post 120 d by a gap to change the performance characteristics of the transformer, for example to increase the reluctance.

A primary winding 150 and a secondary winding 155 are formed around first post 120 b/third post 120 c to form a transformer circuit. Primary and secondary windings 150, 155, respectively, may each have any suitable number of turns and be made from any suitable gauge of insulated wire. In some embodiments primary winding 150 may be interleaved with secondary winding 155 (e.g., the primary winding and the secondary winding arranged in alternating layers), as shown in FIG. 1 , however in other embodiments the primary winding may be twisted with the secondary winding or some other suitable configuration may be used. In some embodiments the interleaving may improve the bandwidth of the transformer and improve noise immunity.

An inductor winding 160 can be formed around first post 120 a/third post 120 c to form an inductor. Inductor winding 160 can have any suitable number of turns and be made from any suitable gauge of insulated wire. Inductor winding may be electrically coupled to primary winding 150, as described in more detail herein. Inductor winding 160, primary winding 150 and secondary winding 155 may be integrally formed between first and second cores 105, 130, respectively, which can be more space efficient than using two separate core assemblies and may be jointly coupled to a common heatsink.

First and second cores, 105, 130, respectively, may be made from any suitable “magnetic” material. In some embodiments first and second cores 105, 130, respectively, are made from the same magnetic material while in other embodiments they are each made from different magnetic materials. In some embodiments one or more of first and second cores 105, 130, respectively, can be made from, but are not limited to, the following “magnetic” materials that have a high magnetic permeability: “soft” (annealed) iron; amorphous metal including a variety of alloys (e.g. Metglas) that are non-crystalline or glassy; powdered metals that consist of metal grains mixed with a suitable organic or inorganic binder, and pressed to desired density; powdered iron; carbonyl iron; hydrogen-reduced iron; molypermalloy which is an alloy of about 2% molybdenum, 81% nickel, and 17% iron; high-flux (Ni—Fe) which is an alloy of about 50-50% of nickel and iron; KoolMU which is an alloy of 6% aluminum, 9% silicon, and 85% iron; nanocrystalline which may be an alloy of a standard iron-boron-silicon alloy, with the addition of smaller amounts of copper and niobium where the grain size of the powder is in the range of 10-100 nanometers and ferrite.

FIG. 2 illustrates a simplified isometric and partially transparent assembled view of the integrated transformer shown in FIG. 1 . As shown in FIG. 2 , first core 105 is mated with second core 130 captivating primary winding 150, secondary winding 155 and inductor winding 160 therebetween. Integrated transformer 100 provides a compact and efficient method of forming a transformer and inductor pair and can be coupled to a heatsink, as described in more detail below. In some embodiments a void 205 defined between first core 105 and second core 130 can be filled with a material such as, for example a thermally conductive potting compound, an electrically insulative polymer, or any other suitable material. In some embodiments one or more surfaces of integrated transformer 100 can be thermally coupled to a heatsink to remove thermal energy from the assembly.

FIG. 3 illustrates an electrical schematic of integrated transformer 100 shown in FIGS. 1 and 2 . As shown in FIG. 3 , primary winding 150 is inductively coupled to secondary winding 155. Inductor winding 160 is coupled in series with primary winding 150 to provide the transformer with an increased series inductance. Primary leads 305 a, 305 b, and secondary leads 310 a, 310 c can be used to couple integrated transformer 100 to a circuit, such as a power converter.

FIG. 4 illustrates a simplified isometric exploded view of an integrated transformer and inductor 400, according to embodiments of the disclosure. Integrated transformer 400 is similar to integrated transformer 100, however integrated transformer 400 has a separate third core, as described in more detail below. Transformer 400 may be or may include any of the components, features, or characteristics of any of the transformers described herein.

First core 405 is made from a first magnetic material and includes a first generally U-shaped body 410 defining a first channel 415. Within first channel 415 is a first post 420 and a first protrusion 425. First channel 415 may have one or more first relief regions 430 that provide room for windings, as described in more detail below.

Second core 435 is made from a second magnetic material and includes a second generally U-shaped body 440 defining a second channel 445. Within second channel 445 is a second post 450 and a second protrusion 455. Second channel 445 may have one or more second relief regions 460 that provide room for windings, as described in more detail below.

A third core 465 is made from a third magnetic material and is generally cylindrical in shape having a first end 470 a opposite a second end 470 b.

First core 405 is configured to be mated to second core 435 such that first and second generally U-shaped bodies 410, 440, respectively, are in physical contact and first post 420 is in contact with second post 450. In some embodiments first post 420 may be separated from second post 450 by a gap to change the performance characteristics of the transformer, for example to increase the reluctance. Further, when in the mated position, first end 470 a of third core 465 is sized and configured to contact first protrusion 425 and second end 470 b is sized and configured to contact second protrusion 455. In further embodiments first protrusion 425 and second protrusion 455 may be removed and first end 470 a may be in contact with a bottom surface of first channel 415 and second end 470 b may be in contact with a bottom surface of second channel 445.

A primary winding 475 and a secondary winding 480 are formed around first post 420/second post 450 to form a transformer circuit. Primary and secondary windings 475, 480, may each have any suitable number of turns and be made from any suitable gauge of insulated wire. In some embodiments primary winding 475 may be interleaved with secondary winding 480, or may be twisted together.

An inductor winding 485 can be formed around third core 465 to form an inductor. Inductor winding 485 can have any suitable number of turns and be made from any suitable gauge of insulated wire. Inductor winding 485 may be electrically coupled to primary winding 475, as described in more detail herein. Inductor winding 485, primary winding 475 and secondary winding 480 may be integrally formed between first and second cores 405, 435, respectively which can be more space efficient than using two separate core assemblies and may be jointly coupled to a common heatsink.

First, second and third cores, 405, 435, 465, respectively, may be made from any suitable “magnetic” material as previously described. In some embodiments first and second cores 405, 435, respectively are made from the same magnetic material and third core 465 is made from a different magnetic material that provides a suitable inductance value for the inductor circuit. In further embodiments first, second and third cores, 405, 435, 465, respectively are each made from different magnetic materials.

FIG. 5A illustrates a simplified exploded view of an integrated transformer and inductor 500, and FIG. 5B illustrates a simplified assembled view of the integrated transformer and inductor, according to embodiments of the disclosure. As shown in FIGS. 5A and 5B, transformer 500 is similar to transformer 100 shown in FIGS. 1-3 , however transformer 500 includes a pair of notches, as described in more detail below. Transformer 500 may be or may include any of the components, features, or characteristics of any of the transformers described herein.

First core 505 is made from a first magnetic material and includes a first generally U-shaped body 510 defining a first channel 515. First and second cuts 520 a, 520 b, respectively are formed in opposite sides of first body 510 into first channel 515. Within first channel 515 is a first post 525 a and a second post 525 b. First channel 515 may have one or more first relief regions 530 that provide room for windings.

Second core 535 is made from a second magnetic material and includes a second generally U-shaped body 540 defining a second channel 545. Third and fourth cuts 520 c, 520 d, respectively are formed in opposite sides of second body 540 into second channel 545. Within second channel 545 is a third post 525 c and a fourth post 525 d. Second channel 545 may have one or more second relief regions 550 that provide room for windings, as described in more detail below.

First core 505 is configured to be mated to second core 535 such that physical contact occurs between first and second generally U-shaped bodies 510, 540, respectively, between first and third post 525 a, 525 c, respectively, and between second and fourth post 525 b, 525 d, respectively. In some embodiments first post 525 a may be separated from third post 525 c by a gap to change the performance characteristics of the transformer, for example to increase the reluctance. Further, first and third cuts 520 a, 520 c, respectively, line up to form first notch 550 a and second and fourth cuts, 520 b, 520 d, respectively line up to form second notch 550 b.

A primary winding 555 and a secondary winding 560 are formed around first and third post 525 a, 525 c, respectively to form a transformer circuit. Primary and secondary windings 555, 560, may each have any suitable number of turns and be made from any suitable gauge of insulated wire. In some embodiments primary winding 555 may be interleaved with secondary winding 560, or may be twisted together.

An inductor winding 570 can be formed around second and fourth post 525 b, 525 d, respectively, to form an inductor. Inductor winding 570 can have any suitable number of turns and be made from any suitable gauge of insulated wire. Inductor winding 570 may be electrically coupled to primary winding 555, as described in more detail herein. Inductor winding 570, primary winding 555 and secondary winding 560 may be integrally formed between first and second cores 505,535, respectively, which can be more space efficient than using two separate core assemblies and may be jointly coupled to a common heatsink.

Integrated transformer 500 provides a compact and efficient method of forming a transformer and inductor pair and can be coupled to a heatsink, as described in more detail below. In some embodiments a void 575 defined between first core 505 and second core 535 can be filled with a material such as, for example a thermally conductive potting compound, an electrically insulative polymer, or any other suitable material. In various embodiments first and second notches 550 a, 550 b, respectively, can provide access for void 575 to be filled with a thermally conductive potting compound and may be used to couple the thermally conductive potting compound directly to a heatsink.

First and second cores, 505, 535, respectively, may be made from any suitable “magnetic” material. In some embodiments first and second cores 505, 535, respectively are made from the same magnetic material while in other embodiments they are each made from different magnetic materials.

FIG. 6A illustrates a simplified exploded view of an integrated transformer and inductor 600, and FIG. 6B illustrates a simplified assembled view of the integrated transformer and inductor, according to embodiments of the disclosure. As shown in FIGS. 6A and 6B, transformer 600 is similar to transformer 500 shown in FIGS. 5A and 5B, however transformer 600 includes a cutout that exposes a portion of the primary winding and the secondary winding, as described in more detail below. Transformer 600 may be or may include any of the components, features, or characteristics of any of the transformers described herein.

First core 605 is made from a first magnetic material and includes a first generally U-shaped body 610 defining a first channel 615. A first relief 620 is formed in one side of first body 610 and into first channel 615. Within first channel 615 is a first post 625 and a second post 630. First channel 615 may have one or more first relief regions 635 that provide room for windings.

Second core 640 is made from a second magnetic material and includes a second generally U-shaped body 645 defining a second channel 650. A second relief 655 is formed in one side of second body 645 and into second channel 650. Within second channel 650 is a third post 670 and a fourth post 675. Second channel 650 may have one or more second relief regions (not shown in FIG. 6A or 6B) that provide room for windings, as described in more detail below.

First core 605 is configured to be mated to second core 640 such that physical contact occurs between first and second generally U-shaped bodies 610, 645, respectively, between first and third post 625, 670, respectively and between second and fourth post 630, 675, respectively. In some embodiments first post 625 may be separated from third post 670 by a gap to change the performance characteristics of the transformer, for example to increase the reluctance. Further, first and second reliefs 620, 655, respectively, line up to form cutout 680 that exposes a portion of primary winding 685 and secondary winding 690.

A primary winding 685 and a secondary winding 690 are formed around first and third posts 625, 670, respectively to form a transformer circuit. Primary and secondary windings 685, 690, may each have any suitable number of turns and be made from any suitable gauge of insulated wire. In some embodiments primary winding 685 may be interleaved with secondary winding 690, or may be twisted together.

An inductor winding 695 can be formed around second and fourth posts 630, 675, respectively, to form an inductor. Inductor winding 695 can have any suitable number of turns and be made from any suitable gauge of insulated wire. Inductor winding 695 may be electrically coupled to primary winding 685, as described in more detail herein. Inductor winding 695, primary winding 685 and secondary winding 690 may be integrally formed between first and second cores 605, 640, respectively, which can be more space efficient than using two separate core assemblies and may be jointly coupled to a common heatsink.

Integrated transformer 600 provides a compact and efficient method of forming a transformer and inductor pair and can be coupled to a heatsink, as described in more detail below. In some embodiments a void 697 defined between first core 605 and second core 640 can be filled with a material such as, for example a thermally conductive potting compound, an electrically insulative polymer, or any other suitable material. In various embodiments cutout 680 can provide access for void 697 to be filled with a thermally conductive potting compound and may be used to couple the thermally conductive potting compound directly to a heatsink. More specifically, in some embodiments primary winding 685 and secondary winding 690 may be directly coupled to a heatsink via thermally conductive potting material without having to transport the thermal energy through first or second core, 605, 640, respectively.

First and second cores, 605, 640, respectively, may be made from any suitable “magnetic” material. In some embodiments first and second cores 605, 640, respectively are made from the same magnetic material while in other embodiments they are each made from different magnetic materials.

FIG. 7A illustrates a simplified exploded view of an integrated transformer and inductor 700, and FIG. 7B illustrates a simplified assembled view of the integrated transformer and inductor, according to embodiments of the disclosure. As shown in FIGS. 7A and 7B, transformer 700 is similar to transformer 500 shown in FIGS. 5A and 5B, however transformer 700 includes an open side that exposes a portion of the primary winding, the secondary winding and the inductor winding as described in more detail below. Transformer 700 may be or may include any of the components, features, or characteristics of any of the transformers described herein.

First core 705 is made from a first magnetic material and includes a first generally L-shaped body 710 defining a first channel 715. Within first channel 715 is a first post 720 and a second post 725. First channel 715 may have one or more first relief regions 730 that provide room for windings.

Second core 735 is made from a second magnetic material and includes a second generally L-shaped body 740 defining a second channel 745. Within second channel 745 is a third post 750 and a fourth post 755. Second channel 745 may have one or more second relief regions (not shown in FIGS. 7A and 7B) that provide room for windings, as described in more detail below.

First core 705 is configured to be mated to second core 735 such that physical contact occurs between first and second generally L-shaped bodies 710, 740, respectively, between first and third posts 720, 750, respectively and between second and fourth posts 725, 755, respectively. In some embodiments first post 720 may be separated from third post 750 by a gap to change the performance characteristics of the transformer, for example to increase the reluctance.

A primary winding 780 and a secondary winding 785 are formed around first and third posts 720, 750, respectively to form a transformer circuit. Primary and secondary windings 780, 785, may each have any suitable number of turns and be made from any suitable gauge of insulated wire. In some embodiments primary winding 780 may be interleaved with secondary winding 785, or may be twisted together.

An inductor winding 790 can be formed around second and fourth posts 725, 755, respectively, to form an inductor. Inductor winding 790 can have any suitable number of turns and be made from any suitable gauge of insulated wire. Inductor winding 790 may be electrically coupled to primary winding 780, as described in more detail herein. Inductor winding 790, primary winding 780 and secondary winding 785 may be integrally formed between first and second cores 705, 735, respectively, which can be more space efficient than using two separate core assemblies and may be jointly coupled to a common heatsink.

Integrated transformer 700 provides a compact and efficient method of forming a transformer and inductor pair and can be coupled to a heatsink, as described in more detail below. In some embodiments a void 760 defined between first core 705 and second core 735 can be filled with a material such as, for example a thermally conductive potting compound, an electrically insulative polymer, or any other suitable material. In various embodiments open side 765 can provide access for void 760 to be filled with a thermally conductive potting compound and may be used to couple the thermally conductive potting compound directly to a heatsink. More specifically, in some embodiments primary winding 780, secondary winding 785 and inductor winding 790 may be directly coupled to a heatsink via thermally conductive potting material without having to transport the thermal energy through first or second core, 705, 735, respectively.

First and second cores, 705, 735, respectively, may be made from any suitable “magnetic” material. In some embodiments first and second cores 705, 735, respectively are made from the same magnetic material while in other embodiments they are each made from different magnetic materials.

FIG. 8A illustrates a simplified exploded view of a transformer 800 and FIG. 8B illustrates a simplified assembled view of the transformer, according to embodiments of the disclosure. As shown in FIGS. 8A and 8B, transformer 800 is similar to integrated transformer 100 shown in FIGS. 1 and 2 , however transformer 800 does not include an inductor winding and the primary and secondary windings are distributed between the two posts, as described in more detail below. Transformer 800 may be or may include any of the components, features, or characteristics of any of the transformers described herein.

Transformer 800 includes two separate magnetic cores. First core 805 is made from a first magnetic material and includes a first generally U-shaped body 810 defining a first channel 815. Within first channel 815 is a first post 820 and a second post 825. First channel 815 may have one or more first relief regions 830 that provide room for windings, as described in more detail below.

Second core 835 is made from a second magnetic material and includes a second generally U-shaped body 840 defining a second channel 845. Within second channel 845 is a third post (not shown) and a fourth post 850. Second channel 845 may have one or more second relief regions that provide room for windings, as described in more detail below.

First core 805 is configured to be mated to second core 835 such that physical contact occurs between first and second generally U-shaped bodies 810, 840, respectively, between first post 820 and third post (not shown) and between second and fourth posts 825, 850, respectively. In some embodiments first post 820 may be separated from third post (not shown) by a gap to change the performance characteristics of the transformer, for example to increase the reluctance. Similarly, in some embodiments second post 825 may be separated from fourth post 850 by a gap.

A primary winding 855 and a secondary winding 860 are formed around first post 820/third post and around second post 825/fourth post 850 to form a transformer circuit. Primary and secondary windings 855, 860, may each have any suitable number of turns and be made from any suitable gauge of insulated wire. In some embodiments primary winding 855 may be interleaved with secondary winding 860, as shown in FIG. 1 , however in other embodiments the primary winding may be twisted with the secondary winding. In some embodiments the interleaving may improve the bandwidth of the transformer and improve noise immunity. The multiple sets of primary windings 855 may be connected in series, parallel or a combination of series and parallel. The multiple sets of secondary windings 860 may be connected in series, parallel or a combination of series and parallel.

First and second cores, 805, 835, respectively, may be made from any suitable “magnetic” material. In some embodiments first and second cores 805, 835, respectively are made from the same magnetic material while in other embodiments they are each made from different magnetic materials.

Transformer 800 provides a compact and efficient method of forming a transformer and can be coupled to a heatsink, as described in more detail below. In some embodiments void 865 defined between first core 805 and second core 835 can be filled with a material such as, for example a thermally conductive potting compound, an electrically insulative polymer, or any other suitable material. In some embodiments one or more surfaces of integrated transformer 800 can be thermally coupled to a heatsink to remove thermal energy from the assembly.

FIG. 9A illustrates a simplified exploded view of a transformer 900 and FIG. 9B illustrates a simplified assembled view of the transformer, according to embodiments of the disclosure. As shown in FIGS. 9A and 9B, transformer 900 is similar to transformer 700 shown in FIGS. 7A and 7B, however transformer 900 does not include an inductor winding and the primary and secondary windings are distributed between the two posts, as described in more detail below. Transformer 900 may be or may include any of the components, features, or characteristics of any of the transformers described herein.

First core 905 is made from a first magnetic material and includes a first generally L-shaped body 910 defining a first channel 915. Within first channel 915 is a first post 920 and a second post 925. First channel 915 may have one or more first relief regions 930 that provide room for windings.

Second core 935 is made from a second magnetic material and includes a second generally L-shaped body 940 defining a second channel 945. Within second channel 945 is a third post 950 and a fourth post 955. Second channel 945 may have one or more second relief regions that provide room for windings, as described in more detail below.

First core 905 is configured to be mated to second core 935 such that physical contact occurs between first and second generally L-shaped bodies 910, 940, respectively, between first and third posts 920, 950, respectively and between second and fourth post 925, 955, respectively. In some embodiments first post 920 may be separated from third post 950 by a gap to change the performance characteristics of the transformer, for example to increase the reluctance. Similarly, in some embodiments second post 925 may be separated from fourth post 955 by a gap.

A primary winding 960 and a secondary winding 965 are formed around first post 920/third post 950 and around second post 925/fourth post 955 to form a transformer circuit. Primary and secondary windings 960, 965, may each have any suitable number of turns and be made from any suitable gauge of insulated wire. In some embodiments primary winding 960 may be interleaved with secondary winding 965, as shown in FIG. 1 , however in other embodiments the primary winding may be twisted with the secondary winding. In some embodiments the interleaving may improve the bandwidth of the transformer and improve noise immunity. The multiple sets of primary windings 960 may be connected in series, parallel or a combination of series and parallel. The multiple sets of secondary windings 965 may be connected in series, parallel or a combination of series and parallel.

Transformer 900 provides a compact and efficient method of forming a transformer and can be coupled to a heatsink, as described in more detail below. In some embodiments void 970 defined between first core 905 and second core 935 can be filled with a material such as, for example a thermally conductive potting compound, an electrically insulative polymer, or any other suitable material. In various embodiments open side 975 can provide access for void 970 to be filled with a thermally conductive potting compound and may be used to couple the thermally conductive potting compound directly to a heatsink. More specifically, in some embodiments primary winding 960 and secondary winding 965 may be directly coupled to a heatsink via thermally conductive potting material without having to transport the thermal energy through first or second core, 905, 935, respectively.

First and second cores, 905, 935, respectively, may be made from any suitable “magnetic” material. In some embodiments first and second cores 905, 935, respectively are made from the same magnetic material while in other embodiments they are each made from different magnetic materials.

Transformers 100, 400, 500, 600, 700, 800 and 900 can include any of the components, features, or characteristics of any of the transformers described herein. For example transformer 100 may include the two separate posts shown in transformer 800 around which the interleaved transformer windings are formed.

In the foregoing specification, embodiments of the disclosure have been described with reference to numerous specific details that can vary from implementation to implementation. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. The sole and exclusive indicator of the scope of the disclosure, and what is intended by the applicants to be the scope of the disclosure, is the literal and equivalent scope of the set of claims that issue from this application, in the specific form in which such claims issue, including any subsequent correction. The specific details of particular embodiments can be combined in any suitable manner without departing from the spirit and scope of embodiments of the disclosure.

Additionally, spatially relative terms, such as “bottom” or “top” and the like can be used to describe an element and/or feature's relationship to another element(s) and/or feature(s) as, for example, illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use and/or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as a “bottom” surface can then be oriented “above” other elements or features. The device can be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Terms “and,” “or,” and “and/or,” as used herein, may include a variety of meanings that also is expected to depend at least in part upon the context in which such terms are used. Typically, “or” if used to associate a list, such as A, B, or C, is intended to mean A, B, and C, here used in the inclusive sense, as well as A, B, or C, here used in the exclusive sense. In addition, the term “one or more” as used herein may be used to describe any feature, structure, or characteristic in the singular or may be used to describe some combination of features, structures, or characteristics. However, it should be noted that this is merely an illustrative example and claimed subject matter is not limited to this example. Furthermore, the term “at least one of” if used to associate a list, such as A, B, or C, can be interpreted to mean any combination of A, B, and/or C, such as A, B, C, AB, AC, BC, AA, AAB, ABC, AABBCCC, etc.

Reference throughout this specification to “one example,” “an example,” “certain examples,” or “exemplary implementation” means that a particular feature, structure, or characteristic described in connection with the feature and/or example may be included in at least one feature and/or example of claimed subject matter. Thus, the appearances of the phrase “in one example,” “an example,” “in certain examples,” “in certain implementations,” or other like phrases in various places throughout this specification are not necessarily all referring to the same feature, example, and/or limitation. Furthermore, the particular features, structures, or characteristics may be combined in one or more examples and/or features.

In the preceding detailed description, numerous specific details have been set forth to provide a thorough understanding of claimed subject matter. However, it will be understood by those skilled in the art that claimed subject matter may be practiced without these specific details. In other instances, methods and apparatuses that would be known by one of ordinary skill have not been described in detail so as not to obscure claimed subject matter. Therefore, it is intended that claimed subject matter not be limited to the particular examples disclosed, but that such claimed subject matter may also include all aspects falling within the scope of appended claims, and equivalents thereof. 

What is claimed is:
 1. A transformer comprising: a first magnetic core defining a first channel and further including first and second posts disposed within the first channel; a second magnetic core defining a second channel and further including third and fourth posts disposed within the second channel, wherein the first magnetic core is coupled to the second magnetic core such that the first post is aligned with the third post and the second post is aligned with the fourth post; a primary winding of wire formed around the first and third posts; a secondary winding of wire formed around the first and third posts; and an inductor winding of wire formed around the second and fourth posts, wherein the inductor winding is connected in series with the primary winding.
 2. The transformer of claim 1 wherein a void is defined between the first and the second magnetic cores and a thermally conductive potting compound is disposed within the void.
 3. The transformer of claim 1 wherein the first post is separated from the third post by a gap.
 4. The transformer of claim 1 wherein the first and the second magnetic cores each have U-shaped bodies.
 5. The transformer of claim 1 wherein the first and the second magnetic cores each have L-shaped bodies.
 6. The transformer of claim 5 wherein, the L-shaped bodies define an open side of the transformer that exposes a portion of the primary winding, a portion of the secondary winding and a portion of the inductor winding.
 7. The transformer of claim 1 wherein the first magnetic core and the second magnetic core define a notch that extends to the first and the second channels.
 8. A transformer comprising: a first magnetic core defining a first channel; a second magnetic core defining a second channel, wherein the first magnetic core is coupled to the second magnetic core; a first post positioned within the first channel and within the second channel, the first post extending from the first magnetic core to the second magnetic core; a second post positioned within the first channel and within the second channel, the second post extending from the first magnetic core to the second magnetic core; a primary winding of wire formed around the first post; a secondary winding of wire formed around the first post; and an inductor winding of wire formed around the second post.
 9. The transformer of claim 8 wherein the inductor winding is connected in series to the primary winding.
 10. The transformer of claim 8 wherein the first post is formed from a portion of the first magnetic core and from a portion of the second magnetic core.
 11. The transformer of claim 8 wherein the second post is formed from a portion of the first magnetic core and from a portion of the second magnetic core.
 12. The transformer of claim 8 wherein the second post is separate from the first magnetic core and the second magnetic core.
 13. The transformer of claim 12 wherein the first magnetic core defines a first protrusion formed in the first channel and wherein the second magnetic core defines a second protrusion within the second channel, and wherein the second post includes a first end that is in contact with the first protrusion and includes a second end that is in contact with the second protrusion.
 14. The transformer of claim 12 wherein the first and second magnetic cores are made from a first magnetic material and wherein the second post is made from a second magnetic material, and wherein the first magnetic material is different than the second magnetic material.
 15. The transformer of claim 8 wherein a void is defined between the first and the second magnetic cores and a thermally conductive potting compound is disposed within the void.
 16. The transformer of claim 11 wherein the first and the second magnetic cores each have U-shaped bodies.
 17. A method of forming a transformer comprises: forming a first magnetic body defining a first channel and further including first and second posts disposed within the first channel; forming a second magnetic body defining a second channel and further including third and fourth posts disposed within the second channel; coupling the first magnetic body to the second magnetic body such that the first post is aligned with the third post and the second post is aligned with the fourth post; forming a primary winding of wire around the first and third posts; forming a secondary winding of wire around the first and third posts; forming an inductor winding of wire formed around the second and fourth posts; and connecting the inductor winding in series with the primary winding.
 18. The method of claim 17 further comprising, forming a notch or cutout in a portion of the first and the second magnetic bodies and depositing a thermally conductive potting compound between the first magnetic body and the second magnetic body.
 19. The method of claim 17 wherein the first and the second magnetic bodies are each U-shaped.
 20. The method of claim 17 wherein the first and the second magnetic bodies are each L-shaped. 